Stitched non-woven textile fabric having varied pattern of raised ribs on one face

ABSTRACT

A non-woven, textile fabric adaptable for use as bedspread, drapery, upholstery or the like material characterized by varied pattern of raised ribs on one face thereof. The fabric comprises a non-woven base reinforced with spaced-apart rows of stitch chains including interconnected stitch loop components on one face and stitch components on the other face of the base, both being formed from a first set of yarns. A second set of yarns is stitched with the first set in selected rows of stitch chains only to form selected double yarn stitch loop components on the one face of the base in the selected rows of stitch chains and diagonally-extending, shogged stitch components on the other face of the base extending back and forth between adjacent selected rows of stitch chains causing the corresponding rows of stitch loop components on the one face of the base to draw closer together and form raised ribs of the base therebetween. The portions of the one face of the base between unselected rows of stitch chains not including any yarns of the second set being substantially planar and non-ribbed thereby providing a varied pattern of raised ribs on the one face of the resulting fabric.

United States Patent [191 Hughes Jan. 1,1974

[ STITCHED NON-WOVEN TEXTIILE FABRIC HAVING VARIED PATTERN 01F RAISED RIBS ON ONE FACE [75] Inventor: George 11. Hughes, Asheville, N.C.

[73] Assignee: National Distillers and Chemical Corporation, New York, NY.

[22] Filed: June 2, 1972 [2]] App]. No.: 258,975

[52] US. Cl 66/192, 161/50, 66/85 A [51] Int. Cl D04b 23/10 [58] Field of Search 66/190-195, 85 A; 112/402, 420; 28/77; 161/50, 52

[56] References Cited UNITED STATES PATENTS 3,365,918 1/1968 Hughes 66/192 222,752 12/1879 Townsend 66/192 3,260,640 7/1966 Owen 161/50 3,565,025 2/1971 Owen, Sr... 28/77 3,635,785 1/1972 Hughes 161/50 3,649,428 4/1972 Hughes 161/50 3,664,157 5/1972 Kochta et a1. 66/190 2,890,579 6/1959 Mauersberger 66/192 FOREIGN PATENTS OR APPLICATIONS 512,488 9/1939 Great Britain 66/192 Primary Examiner-.lames Kee Chi A!!0rneyWarley L. Parrott [57] ABSTRACT A non-woven, textile fabric adaptable for use as bedspread, drapery, upholstery or the like material characterized by varied pattern of raised ribs on one face thereof. The fabric comprises a non-woven base reinforced with spaced-apart rows of stitch chains including interconnected stitch loop components on one face and stitch components on the other face of the base, both being formed from a first set of yarns. A second set of yarns is stitched with the first set in selected rows of stitch chains only to form selected double yarn stitch loop components on the one face of the base in the selected rows of stitch chains and diagonally-extending, shogged stitch components on the other face of the base extending back and forth between adjacent selected rows of stitch chains causing the corresponding rows of stitch loop components on the one face of the base to draw closer together and form raised ribs of the base therebetween. The portions of the one face of the base between unselected rows of stitch chains not including any yarns of the second set being substantially planar and non-ribbed thereby providing a varied pattern of raised ribs on the one face of the resulting fabric.

10 Claims, 15 Drawing Figures PATENTEU 1191*? 3,782,137

sum 1 BF 4 STITCHED NON-WOVEN TEXTILE FABRIC HAVING VARIED PATTERN F RAISED RIBS ON ONE FACE This invention relates generally to a stitched, nonwoven textile fabric adaptable for use as bedspread, drapery, upholstery or the like material and characterized by a varied pattern of raised ribs on one face thereof.

I-Ieretofore, various types of non-woven textile fabrics have been formed by stitching machines which stitch non-woven webs, including a batt of textile fibers for reinforcing the webs. These fabrics have included ribbed surfaces and non-ribbed surfaces and have been utilized for a number of end products including bedspreads, blankets, draperies, outerwear, linings, innerwear, etc. Various constructions of such prior products may be seen in US. Pat. Nos. 3,260,640; 3,329,552; 3,365,918 and 3,395,065, all of which are assigned to the assignee of the present invention.

All these prior products, disclosed in assignees prior patents, have been stitched-on a machineknown commercially as the Arachne machine which is fully described in assignees above US. Pat. No. 3,365,918. However, all these prior products and all other commercially known stitched non-woven products have heretofore all had surfaces or faces which were unvaried or uniform in stitched appearance and design. Those products which had ribbed surfaces included ribs between each row of stitches in the fabric. While these products have been highly commercially successful, they did not provide varied ribbed patterns and designs which have been found desirable in bedspread, drapery, upholstery or the like material.

Accordingly, it is the object of the present invention to provide a stitched non-woven textile fabric adaptable for use as bedspread, drapery, upholstery or the like material which includes a varied pattern of raised ribs on the one face thereof.

It has been found by this invention that the above object may be accomplished by providing a non-woven textile fabric comprising a three-dimensional, nonwoven base having outer faces and a plurality of longitudinally-extending, spaced-apart, elongate, generally parallel, continuous rows of stitch chains embedded in the base and passing from one face of the base to the other face of the base for reinforcing the base. The rows of stitch chains comprise longitudinallyextending rows of interconnected stitch loop components on one face of the base and stitch components on the other face of the base.

A first set of yarns forms the stitch chains so that each of the stitch loop components is formed from one yarn of the first set. A second set of yarns is stitched with the first set of yarns in selected rows of stitch chains only to form selected double yarn stitch loop components on the one face of the base in the selected rows of stitch chains. The second set of yarns also forms diagonally-extending, shogged stitch components on the other face of the base extending back and forth between adjacent selected rows of stitch chains causing the corresponding rows of stitch loop components on the one face of the base to draw closer together and form raised ribs of the base therebetween on the one face of the base. The portions of the one face of the base between unselected rows of stitch chains not including any yarns of the second set of yarns is substantially planar and non-ribbed, thereby providing a varied pattern of raised ribs on the one face of the resulting fabric.

Preferably, the second set of yarns comprises heavier denier yarns than the yarns forming the first set of yarns for causing the corresponding rows of stitch loop components on the one face of the base to draw closer together and form raised ribs of the base therebetween on the one face of the base. The selected rows of stitches, for stitching of the second set of yarns with the first set of yarns, may vary according to the desired pattern or configuration of raised ribs on the one face of the resulting fabric. While several different designs are illustrated in the drawing and will be described in detail hereinafter, it is to be understood that many other specific arrangements and designs of raised ribs may be produced utilizing the 'basic novel concepts of this invention.

Some of the objects and advantages of this invention having been stated, other objects and advantages will appear as the description proceeds when taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of a fragmentary portion of a first design of a stitched non-woven textile fabric constructed in accordance with this invention;

FIG. 2 is an enlarged fragmentary perspective diagrammatic view illustrating the stitch construction utilized in a portion of the fabric of FIG. 1;

FIG. 3 is an enlarged perspective view of one face of a portion of the fabric of FIG. 1;

FIG. 4 is a perspective view of the other face of the fabric illustrated in FIG. 3;

FIG. 5 is perspective view of a fragmentary portion of another design of a stitched non-woven textile fabric constructed in accordance with this invention;

FIG. 6 is an enlarged fragmentary perspective diagrammatic view illustrating the stitch construction utilized in a portion of the fabric of FIG. 5;

FIG. 7 is an enlarged perspective view of one face of a portion of the fabric of FIG. 5;

FIG. 8 is a perspective view of the other face of the fabric illustrated in FIG. 7;

FIG. 9 is a perspective view of a fragmentary portion of another design of a stitched non-wovn textile fabric constructed in accordance with this invention;

FIG. 10 is an enlarged fragmentary perspective diagrammatic view illustrating the stitch construction utilized in a portion of the fabric of FIG. 9;

FIG. 11 is an enlarged perspective view of one face of a portion of the fabric of FIG. 9;

FIG. 12 is a perspective view of the other face of the fabric illustrated in FIG. 11;

FIGS. 13, 14 and 15 are fragmentary perspective views of portions of stitched non-woven textile fabrics produced in accordance with this invention and illustrating further designs of raised ribs.

Referring now to the drawings, FIGS. 1-4, FIGS. 5-8 and FIGS. 9-12 illustrate three designs or variations of non-woven textile fabrics constructed in accordance with this invention. These fabrics vary only in specific details of the stitch construction and like reference characters will be utilized in all three of these fabric designs to designate the same components.

All of these fabrics of FIGS. 1-4, FIGS. 5-8 and FIGS. 9-12 are generally designated by the reference numeral 10. The non-woven fabrics 10 comprise a three-dimensional, non-woven base or core 11 having outer faces 12 and 13.

The base or core 11 is preferably a batt of non-woven fibers 14 in which the individual fibers 14 extend in the transverse or widthwise direction of the batt l1 and the ultimate fabric 10. The batt of fibers 14 may be formed by any conventional carding or garnetting machine and cross-lapped for orienting the fibers in the transverse or widthwise direction of the batt. While the batt of nonwoven fibers 14 is the preferred form of the base or core 11, it is within the concepts of this invention to utilize other non-woven bases or cores, such as foam or any material susceptible to being stitched for reinforcement.

The non-woven fabric further comprises a plurality of longitudinally-extending, spaced-apart, elongate, generally parallel, continuous rows of stitch chains embedded in the base 11 and passing from one face 12 of the base 11 to the other face 13 of the base 11 for reinforcing the base. The rows of stitch chains 15 comprise longitudinally-extending rows of interconnected stitch loop components on the one face 12 of the base 11 and stitch components 21 on the other face 13 of the base 11.

A first set of yarns Y-l forms all of the stitch chains 15 so that each of the stitch loop components 20 and the stitch components 21 are formed from a yarn of the first set Y-l.

A second set of yarns Y-2 is stitched with the first set of yarns in selected rows of stitch chains only (the selected rows being indicated in the drawings by the reference character S in parenthesis after the reference numeral 15) to form selected double yarn stitch loop components 20 on the one face 12 of the base 11 in the selected rows of stitch chains (the double yarn stitch loops being apparent in the drawings from the single yarn stitch loops and no separate reference character is given). The second set of yarns Y-2 also forms diagonally-extending, shogged stitch components 25 on the other face 13 of the base 11 which extend back and forth between adjacent selected rows of stitch chains 15 (S) causing the corresponding rows of stitch loop components 20 on the one face 12 to draw closer together and form raised ribs R of the base 11 therebetween on the one face 12 of the base 11.

The portions of the one face 12 of the base 11 between unselected rows of stitch chains 15 are substantially planar and non-ribbed. The above-described construction results in a varied pattern of a ribbed and planar surface on the one face 12 of the fabric 10.

The stitching yarns Y1 and Y-2 may be of various natural or synthetic fibers or blends but continuous filament synthetic yarns, e.g. nylon yarn or polyester yarn, are advantageous to obtain relatively high strength and to prevent breakage in the manufacturing operation and to give tensile strength in the finished fabric.

It has been found by this invention that, if the second set of stitching yarns Y-2 comprises heavier denier yarns than the yarns forming the first set of yarns Y-l, the formation of ribs R between selected rows of stitch chains 15 (S) will be easier formed. This is because the heavier denier yarns forming the second set of stitching yarns Y-2 increases the tension in the stitch construction of the selected rows of stitch chains 15 (S) utilizing the yarns Y-2. In accordance with a preferred commercial form of this invention, it has been found that the above may be accomplished by utilizing 70 denier nylon yarn as the first set of yarns Y-l and 400 denier nylon yarn as the second set of yarns Y-2.

Referring now specifically to the design of the fabric 10, illustrated in FIGS. 1-4, it may be seen therein that the rows of stitch chains 15 and the stitch loop components 20 on the one face 12 and the stitch components 21 on the other face 13 formed from the first set of yarns Y-l comprise straight chain stitching in which the stitch components 21 are in the form of longitudinallyextending, straight line stitch components extending along each of the rows of stitch chains 15.

Further, in the fabric 10 of FIGS. 1-4, the selected rows of stitch chains 15 (S) in which the second set of yarns Y-2 is stitched with the first set of yarns Y-l comprise adjacent rows of stitch chains 15 and the diagonally-extending, shogged stitch components 25 formed from the second set of yarns Y-2 on the other face 13 extend back and forth between the adjacent rows of stitch chains 15, as may be seen clearly in FIGS. 2 and 4. Also, the double yarn stitch loop components 20 on the one face 12 formed from both the first and second sets of yarns Y-l, Y-2 comprise every other or alternate stitch loops in the selected stitch chains.

Further, in the fabric 10 of FIGS. 1-4, unselected rows of stitch chains 15, which do not have the second set of yarns Y-2 stitched with the first set of yarns Y-1, comprise two stitch chains 15 between each pair of selected stitch chains 15 (S). The resulting fabric 10 has a design on the one face 12 in which a raised rib alternates with a planar surface having two rows of stitch chains therein.

Referring specifically to the design of the fabric 10 of FIGS. 5-8, it may be seen therein that the rows of stitch chains 15 and the stitch loop components 20 on the one face 12 and the stitch components 21 on the other face 13 formed from the first set of yarns Y-l comprise straight chain stitching in which the stitch components 21 are in the form of longitudinally-extending, straight line stitch components extending along each of the rows of stitch chains 15.

In the fabric of FIGS. 5-8, the selected rows of stitch chains 15 (S) in which the second set of yarns Y-2 is stitched with the first set of yarns Y-l comprise the outer rows of stitch chains 15 in groups of three adjacent rows of stitch chains and the diagonally-extending, shogged stitch components 25 formed from the second set of yarns Y-2 on the other face 13 extend back and forth between the outer rows of stitch chains in se lected groups of three adjacent rows of stitch chains, as may be seen clearly in FIGS. 6 and 8. Also, the double yarn stitch loop components 20 on the one face 12 formed from both the first and second sets of yarns Y-l, Y-2 comprise every other or alternate stitch loops in the selected stitch chains.

In the fabric 10 of FIGS. 5-8, unselected rows of stitch chains 15 which do not have the second set of yarns Y-2 stitched with the first set of yarns Y-'1 comprise two stitch chains 15 between each selected group of stitch chains 15 (S). The resulting fabric 10 has a design on the one face 12 in which a pair of adjacent raised ribs alternates with a planar surface having two rows of stitch chains therein.

Referring now specifically to the design of the fabric 10, illustrated in FIGS. 9-12, it may be seen therein that the rows of stitch chains 15 and the stitch loop components 20 on the one face 12 and the stitch components 21 on the other face 13 formed from the first set of yarns Y-l comprise shogged chain stitching in which the stitch components 21 are in the form of lected stitch chains 15 (S), as may be seen clearly in' FIGS. and 12. Also, the double yarn stitch loop components 20 on the one face 12 formed from both the first and second sets of yarn Y-l, (-2 comprise every other or alternate stitch loops in the selected stitch chains.

in the fabric 10 of FIGS. 9 12, unselected rows of stitch chains which do not have the second set of yarns Y-2 stitched with the first set of yarns Y-l comprise two stitch chains 15 between each pair of selected stitch chains 15 (S). The resulting fabric 10 has a design on the one face 12 in which a raised rib alternates with a planar surface having two rows of stitch chains therein.

Referring now to FIGS. 13-15, these figures illustrate exemplary, alternate designs of ribbed and planar surfaces on fabrics which may be formed with the concepts described above in connection with the invention. As may be seen in FlG. 113, the fabric 10 has a design on the one face 12 in which a pair of adjacent raised ribs alternate with a planar surface having four rows of stitch chains 15 therein.

The fabric 10 of FIG. 14 illustrates a design on the one face 12 having a portion utilizing 6 adjacent raised ribs, a planar portion having 10 rows of stitch chains therein, a ribbed and planar portion having a single rib alternating with a planar surface having a single row of stitches therein, etc.

The design of the fabric of F IG. 15 further shows variations in a pattern of riased ribs and planar surface having rows of stitches therein.

As may be seen from the above description and accompanying drawings, this invention has provided a non-woven, textile fabric adaptable for use as beds'pread, drapery, upholstery or the like material which is characterized by a varied pattern of raised ribs on one face thereof. The concepts of this invention include any combination of the specifically described stitch constructions and raised ribs and planar surfaces and is not intended to be limited by the specific examples illustrated in the drawings and described above.

In the drawings and specification there have been set forth preferred embodiments of this invention and, although specific terms have been employed, they are used in a generic and descriptive sense only and not for purposes of limitation.

That which is claimed is:

1. A non-woven, textile fabric adaptable for use as bedspread, drapery, upholstery or the like material and characterized by a varied pattern of raised ribs on one face thereof, said fabric comprising:

a three-dimensional, non-woven base having outer faces;

a plurality of longitudinally-extending, spaced-apart, elongate, generally parallel, continuous rows of stitch chains embedded in said base and passing from one face of said base to the other face of said base for reinforcing said base, said rows of stitch chains comprising longitudinally-extending rows of interconnected stitch loop components on one face of said base and stitch components on the other face of said base;

first set of yarns forming said stitch chains so that each of said stitch loop components is formed from one yarn of said first set; and

a second set of yarns stitched with said first set of yarns in selected rows of stitch chains only to form selected double yarn stitch loop components on the one face of said base in said selected rows of stitch chains and diagonally-extending, shogged stitch components on the other face of said base extending back and forth between adjacent selected rows of stitch chains causing the corresponding rows of stitch loop components on the one face of said base to draw closer together and form raised ribs of said base therebetween on the one face of said base, the portions of the one face of said base between unselected rows of stitch chains not including any yarns of said second set of yarns being substantially planar and non-ribbed thereby providing a varied pattern of raised ribs on the one face of the resulting fabric.

2. A non-woven, textile fabric, as set forth in claim 1, in which said second set of yarns comprises heavier denier yarns than the yarns forming said first set of yarns for causing said corresponding rows of stitch loop components on the one face of said base to draw closer together and form riased ribs of said base therebetween on the one-face of said base.

3. A non-woven, textile fabric, as set forth in claim 1, in which said base comprises a batt of textile fibers in which the fibers of said batt extend in the transverse direction thereof.

4. A non-woven, textile fabric, as set forth in claim I, in which said stitch components on the other face of said base forming part of each of said stitch chains comprises longitudinally-extending, straight line stitch components extending along each of said rows of stitch chains and formed from said first set of yarns.

5. A non-woven, textile fabric, as set forth in claim 1, in which said stitch components on the other face of said base forming a part of each of said stitch chains comprising diagonally-extending, shogged stitch components extending back and forth between adjacent rows of stitch chains and formed from said first set of yarns.

6. A non-woven, textile fabric, as set forth in claim 1, in which the selected rows of stitch chains having said diagonally-extendingshogged stitch components formed from said second set of yarns extending back and forth therebetween comprise pairs of adjacent rows of stitch chains.

7. A non-woven, textile fabric, as set forth in claim 6, in which unselected rows of stitch chains extend between said selected pairs for forming non-ribbed portions therebetween.

8. A non-woven, textile fabric, as set forth in claim 1, in which the selected rows of stitch chains having said diagonally-extending shogged stitch components formedfrom said second set of yarns extending back and forth therebetween comprise the outer rows of stitch chains in groups of three adjacent rows of stitch chains to form two adjacent raised ribs between said 10. A non-woven, textile fabric, as set forth in claim 1, in which said double yarn stitch loop components formed from yarns of each of said first and second sets comprise every other or alternate stitch loop components in said selected stitch chains. 

1. A non-woven, textile fabric adaptable for use as bedspread, drapery, upholstery or the like material and characterized by a varied pattern of raised ribs on one face thereof, said fabric comprising: a three-dimensional, non-woven base having outer faces; a plurality of longitudinally-extending, spaced-apart, elongate, generally parallel, continuous rows of stitch chains embedded in said base and passing from one face of said base to the other face of said base for reinforcing said base, said rows of stitch chains comprising longitudinally-extending rows of interconnected stitch loop components on one face of said base and stitch components on the other face of said base; a first set of yarns forming said stitch chains so that each of said stitch loop components is formed from one yarn of said first set; and a second set of yarns stitched with said first set of yarns in selected rows of stitch chains only to form selected double yarn stitch loop components on the one face of said base in said selected rows of stitch chains and diagonally-extending, shogged stitch components on the other face of said base extending back and forth between adjacent selected rows of stitch chains causing the corresponding rows of stitch loop components on the one face of said base to draw closer together and form raised ribs of said base therebetween on the one face of said base, the portions of the one face of said base between unselected rows of stitch chains not including any yarns of said second set of yarns being substantially planar and nonribbed thereby providing a varied pattern of raised ribs on the one face of the resulting fabric.
 2. A non-woven, textile fabric, as set forth in claim 1, in which said second set of yarns comprises heavier denier yarns than the yarns forming said first set of yarns for causing said corresponding rows of stitch loop components on the one face of said base to draw closer together and form raised ribs of said base therebetween on the one face of said base.
 3. A non-woven, textile fabric, as set forth in claim 1, in which said base comprises a batt of textile fibers in which the fibers of said batt extend in the transverse direction thereof.
 4. A non-woven, textile fabric, as set forth in claim 1, in which said stitch components on the other face of said base forming part of each of said stitch chains comprises longitudinally-extending, straight line stitch components extending along each of said rows of stitch chains and formed from said first set of yarns.
 5. A non-woven, textile fabric, as set forth in claim 1, in which said stitch components on the other face of said base forming a part of each of said stitch chains comprising diagonally-extending, shogged stitch components extending back and forth between adjacent rows of stitch chains and formed from said first set of yarns.
 6. A non-woven, textile fabric, as set forth in claim 1, in which the selected rows of stitch chains having said diagonally-extending shogged stitch components formed from said second set of yarns extending back and forth therebetween comprise pairs of adjacent rows of stitch chains.
 7. A non-woven, textile fabric, as set forth in claim 6, in which unselected rows of stitch chains extend between said selected pairs for forming non-ribbed portions therebetween.
 8. A non-woven, textile fabric, as set forth in claim 1, in which the selected rows of stitch chains having said diagonally-extending shogged stitch components formed from said second set of yarns extending back and forth therebetween comprise the outer rows of stitch chains in groups of three adjacent rows of stitch chains to form two adjacent raised ribs between said three adjacent rows of stitch chains in each selected group.
 9. A non-woven, textile fabric, as set forth in claim 8, in which unselected rows of stitch chains extend between said selected groups for forming non-ribbed portions therebetween.
 10. A non-woven, textile fabric, as set forth in claim 1, in which said double yarn stitch loop components formed from yarns of each of said first and second sets comprise every other or alternate stitch loop components in said selected stitch chains. 